FBE COATED TMT

An introduction
The need
Rebars provide strength and shape to concrete structures, but are vulnerable to the
problem of corrosion, which effects the life of buildings & structures. In order to extend
the useful life, methods are employed to fight corrosion.
CRS grade Rebars: Stainless Rebars: FBE coated Rebars:
They provide resistance to They provide excellent They provide good
corrosion by micro-alloying resistance to corrosion and resistance to corrosion by
with Cu, P, Ni, Cr etc. providing a passive layer
are recommended for usage
This is a cost effective solution between steel and corrosive
in extreme conditions. environment. It is
to fight corrosion.
Cost wise they are more estimated that the life of
CRI being around 1.8, it than two times costly such structures lasts more
enhances the life by around compared to MS rebar and than 100 years and as such
80% at a marginal increase in many infra project
steel cost. this puts a barrier in customers are preferring
widespread usage. these bars as an option to
Projects customers prefer to compromise the cost. The
have a longer life expectancy Welding of these bars
and therefore do not prefer require special procedure cost of coating is approx.
usage of this product. Retail 10-12K/ Ton, which is found
and thus welding at site is advantageous in life cycle
customer may prefer to use it difficult. cost calculations
being cost effective, if properly
educated
 FBE Coated rebar
Fusion bonded epoxy (FBE) coating of steel materials is primer less,
one-part, heat curable, thermosetting powdered epoxy coating which is
designed to provide maximum corrosion protection to the substrate
steel. It is a coating of very fast curing, thermosetting protective
powder which utilizes heat to melt and adhere the coating material to
the steel substrate.
It employs specially selected epoxy resins. The epoxy is formulated in
order to meet the specifications related to protection of steel as an
anti-corrosion coating. Heat cured FBE coatings are 100 % solids
consisting of thermosetting materials which achieve a high bond to
metal surface as a result of a heat generated chemical reaction.

IS 13620 : 1993 is the governing BIS specification for FBE coated bars
Epoxy coated rebar
• A fusion based epoxy coating is applied with
electrical charge to already cleaned steel
rebar through shot blasting
• The epoxy coating acts as a protective layer
and prevents the corrosion of steel Image Space

• Epoxy coating of rebar has no effect on the

bond strength between concrete and steel
• The epoxy coating is recommended by most
of the project designers as the best method
for prevention of corrosion.
• Normal RCC structure life is estimated to be Image Space
around 25-30 years, in case of Epoxy
coating, this is enhanced to 100+ years.

4
Epoxy--Coated Reinforced Bars
Epoxy
• Fusion bonded epoxy coating, also known as fusion -bond epoxy powder coating and
commonly referred to as FBE coating, is an epoxy-based powder coating that is widely
used to protect TMT bars. FBE coatings are thermoset polymer coatings. The name
fusion-bond epoxy is due to resin cross-linking and the application method, which is
different from a conventional paint. The resin and hardener components in the dry
powder FBE stock remain un-reacted at normal storage conditions.
• At typical coating application temperatures, usually in the range of 200 to 240 °C, the
contents of the powder melt and transform to a liquid form. The liquid FBE film wets and
flows onto the steel surface on which it is applied, and soon becomes a solid coating by
chemical cross-linking, assisted by heat. This process is known as “fusion bonding”.
• The chemical cross-linking reaction taking place in this case is irreversible. Once the
curing takes place, the coating cannot be returned to its original form by any means.
Application of further heating will not “melt” the coating and thus it is known as a
thermoset coating.
• FBE coated bars are covered under BIS 13620/93
 Epoxy--Coating process
Epoxy
Regardless of the shape and type of steel
surface to be coated, the FBE powder coating
application has seven essential stages:
• Stage 1: The steel cleaning & surface
preparation - Airless (Wheel Blast) Shot
Blasting Process.
• Stage 2: Pre-Heating to recommended FBE
powder application temperature. (Induction
heating).
• Stage 3: Coating - Fusion Bonded Epoxy
Coating.
• Stage 4: Curing.
• Stage 5: Water Quenching.
• Stage 6: Unloading.
• Stage 7: Inspection.
 Market potential
As per sectarian growth projected by MoS, TMT/ Structures/ Plates/ Coils are
expected to grow @ 21% CAGR. Major drivers are Infrastructure, Power & Railways.
It is estimated that TMT market will grow @ 8~10% CAGR in line with GDP growth

Projected
Current %
demand
Sector demand Growth
2030-31
(mTPA) CAGR
(mTPA)
Infrastructure 9.5 90 61%
Construction 23.5 45 7%
Power & Energy 3 11 19%
Railways 2 5 11%
Total 38 151 21%
Heading Values
Current Consumption
28
ImTPA)
Time
CAGr
Projection (mTPA)
10
8%
60
Source : Draft National Steel Policy - 2017
Addltional
32
requirement (mTPA)
 Growth drivers
Infrastructure Airports Railways Power
The infrastructure More and more The Dedicated Rail The government
sector accounts for 9 modern and private Freight Corridor targets capacity
per cent of steel airports are expected (DRFC) network addition of 88.5 GW
consumption and to be set up expansion would be under the 12th Five-
expected to increase Airports in the country enhanced in future Year Plan (2012–17)
11 per cent by 2025- witnessed a total 34.4 crore Gauge conversion, and around 100 GW
26. passengers during FY 2018- setting up of new lines under the 13th Five-
Due to such a huge 2019, a growth of 11.6% and and electrification Year Plan (2017–22)
investment in number of operational airports would drive steel As of March 31, 2019, the
infrastructure the stood at 126 in FY16 demand total installed capacity of
demand for long steel Development of Tier- At present 498 Railway all energy sources put
products would II city airports would projects including 188 New together stood at about 356
increase in the years sustain consumption Lines, 55 Gauge GW (excluding captive power
ahead Growth Conversion and 255 of 51.5
Estimated steel Doubling Projects are in GW),the thermal sector
consumption in different stages of accounted for 226 GW,
airport building is execution/planning/sanctio followed by renewable at
likely to grow more n. The total length of about 78 GW, hydro at 45 GW
than 20 per cent over these projects is 49,069 and nuclear at about 7 GW.
next few years km costing Rs 6.75 Lakh
Crore.
 Scope of usage in projects
STEEL GROWTH DRIVEN BY CONSTRUCTION & INFRASTRUCTURE
Investment in infrastructure by NITI Aayog is expected to expand at a CAGR of 14.5 per cent
over FY12–17
Investment of USD 650 billion in the urban infrastructure sector is expected in the next 20
years
This increase in infrastructure investment is set to raise steel demand by roughly 18.75 mtpa
Source : Draft National Steel Policy – 2017
It is estimated that Rebar consumption should grow at around 8-9% CAGR post the COVID-19 scenario

On Page 96/489, Annexure B of MINISTRY’S TECHNICAL CIRCULARS AND DIRECTIVES ON NATIONAL

HIGHWAYS AND CENTRALLY SPONSORED ROAD AND BRIDGE PROJECTS it is specified
Quote
“EPOXY-COATED STEEL REINFORCING BAR This item of work shall consist of furnishing fabricating
coating and placing epoxy-coated steel reinforcing bars in accordance with the plans, the standard
specifications and these special provisions. The coating material shall be applied by the electrostatic
spray method or the electrostatic fluidized-bed method “
Unquote
 TMT Market Size Per Annum
Source: Industry Survey (,000 tons)

Region State Consumption/ month

Retail Project Total
Jharkhand 504 576 1080
Chattisagarh 156 144 300
Bihar 600 840 1440
Madhya Paradesh 420 960 1380
East & Central
NE 276 324 600
Odisha 444 456 900
Bengal 720 780 1500
Sub Total 3120 4080 7200
Delhi NCR 360 576 936
Haryana 384 816 1200
Himanchal 120 120 240
J&K 144 216 360
North Panjab 540 540 1080
Rajsthan 480 720 1200
Uttar Pradesh 720 1200 1920
Uttaranchal 144 156 300
Sub Total 2892 4344 7236
Andhra Pradesh 480 600 1080
Gujraat 480 600 1080
Karnataka 900 1140 2040
Kerala 360 480 840
South & West
Maharastra& Goa 660 1920 2580
Tamil Nadu 348 372 720
Telengana 360 540 900
Sub Total 3588 5652 9240
Grand Total 9600 14076 23676
Annual Consumption 115200 168912 284112
 Are FBE-Coated Bars environmentally friendly?

Epoxy-Coated Steel Reinforcing Bar have the following sustainable

attributes:
• Reinforcing bars can be made using recycled steel
• Can be readily recycled after use
• Manufacture using low amounts of energy compared with other
systems
• The coating process produces no VOCs during manufacture or use
• Structures that use epoxy-coated steel reinforcing bar are more
durable that those that do not
• Epoxy-coated bars are locally available
 Other FBE coated Reinforcing Bars FAQ’s
How are the types of epoxy-coated reinforcing bars identified?
In general, a green color coating is used to 54 identify bars that meet ASTM A775/A775M while a
purple or gray color coating is used 55 to identify bars that meet ASTM A934/A934M. Typical bar
markings on the steel are 56 readily visible on the epoxy-coated bars through the coating.
Do epoxy-coated reinforcing bars have the same weight per foot as normal “black” carbon reinforcing
steel bars?
Yes, epoxy-coated reinforcing bars have the same weight per foot as normal “black” 63 carbon
reinforcing steel bars.
What is the effect of damage on the bar performance?
Epoxy-coated reinforcing steel without damage will perform better than bars with undamaged
coatings; however, field and laboratory data has shown that even bars with damage perform
significantly better than uncoated bars. Essentially all tests evaluating epoxy-coated reinforcing steel
are conducted using bars with deliberate damage to simulate worst-case situations.
 Other FBE coated Reinforcing Bars FAQ’s
Is it better to lap splice or mechanically couple epoxy-coated reinforcing bars?
Epoxy-coated reinforcing steel may be spliced using either lap splices or mechanical couplers.
Use of the particular method depends on many factors and this will likely become an economic
decision. For the smaller bar sizes, the “extra” length of epoxy coated steel bar to facilitate the
splice requirements will likely be cheaper than the selected coupler. For the larger bar sizes, the
coupler becomes more economical than the “extra” length of bar used to make the splice. A
mechanical coupler may, however, be a better alternative given job specific constructability
conditions, congestion issues, and/or spacing requirements.
Are there any issues to using couplers with epoxy-coated steel bars?
When couplers are used, they should be inspected for any coating damage prior to placement
of concrete. If damage is observed, the steel should be lightly cleaned to remove any surface
corrosion and coated with an approved two-part epoxy coating, formulated for use with epoxy-
coated reinforcing steel.
 Other FBE coated Reinforcing Bars FAQ’s
Are there any special handling requirements for epoxy-coated reinforcing steel?
Recommendations include:
• When lifting individual bars or bundles of epoxy-coated reinforcing bars, spreader bars or strong backs with
multiple pick-up points shall be used to minimize sags.
• Synthetic or padded slings should be used and at no time should epoxy-coated reinforcing bars be lifted using
bare chains or cables.
• Bundles of epoxy-coated reinforcing bars should be stored off the ground on suitable materials, such as timber
cribbing.
• Epoxy-coated reinforcing bars should be stored separately from uncoated carbon steel reinforcing bars to
prevent abrasion of coating.
• During storage and shipping, all contact points (e.g. trailers, storage racks) should be wood or plastic-lined.
• Epoxy-coated reinforcing bars should be covered using opaque polyethylene sheeting or other suitable opaque
material if they are to be stored outdoors for more than two months.
• Epoxy-coated bars should be protected against coating damage through appropriate lifting, handling, placing
and concrete placement operations.
• During placement, bars should be lifted and set in place. Epoxy-coated reinforcing bars should not be dragged
into place and other materials shall not be dragged across placed epoxy-coated reinforcing bars.
• Movement of personnel and materials across the epoxy-coated bars should beminimized.
Why invest in a FBE plant??
• In order to sustain in business, growth in turnover is must. This prepares
the organization for any eventuality
• First turnover growth comes from increase in sales volumes. This has
limitations with the production capacity and change in size mix to have
higher yield or outsourcing are only options available.
• Second turnover growth comes with the annual inflation and all producers
have no other option but to pass on the cost increase to customer.
• Third option is to go for change in product mix and increase share of value
added products'/ services.
• Finally, it is the brand equity, which gets the much desired premium on the
products and this can be done by investing heavily on improving customer
delight and aggressive branding activities.
FBE plant adds value to the product and being a service oriented
activity, can add substantial value to the product line.
 FBE Project costing – Base Indore – Jan’19
Capital cost Rs. Lakhs Amount
Land 100.00 Head (Rs. Lakhs/
Shed 90.00 month)
Equipments 550.00 Income
Electrical & Others 14.00 From Sale of FG @ 11000/PMT 330.00
Office building & others 15.00
Total Income 330.00 a
Boundary wall 1300 Feet, 8"X9'high @ 1700/ft 22.10
Hardfacing of land 5500m3, @350/cu Mtr 19.25 Expenses
Total Capital 810.35 Operating expenses
Operating cost @ 6000/PMT 180.00
Since the project works on the Labor @ 700/PMT 24.50
Operating expenses (R&M) @700/MT 24.50
concept of a service center where Total Operating expenses 204.50 b
customer delivers the material for Fixed cost
coating and is sent back to the site Interest @12% on capital 8.40 c
Depreciation @ 10% on Machinery 4.58 d
after coating. Working capital Staff salaries (including security) 5.00 e
requirement is minimized only to the Total Fixed cost 17.99 f
tune of spares and consumables, EBIDTA 120.50 (a-b-e)
PBT/ Mon 107.51 (a-b-f)
which is minimal.
PBT/ Annum 1,290.16
 Cost break up of house construction
Site Size: 30x50 site house construction cost (Ground + 1, 3 BHK) up
to 2125 Sq. ft built up area.
Total cost of house ownership 7,437,500
Cost share Overall
Material
Materials Required Quantity Unit in Mat. Cost
cost (Rs.)
Cost share
TMT Steel 7.6 Tonnes 357,200 29% 5%
Cement 930 Bags 337,590 27% 5%
Plastering M Sand 147 Tonnes 205,800 17% 3%
Concrete M Sand 65 Tonnes 61,750 5% 1%
40mm Jelly 513 Cft 12,825 1% 0%
20mm Jelly 2996 Cft 74,900 6% 1%
6" Concrete Block 3120 Blocks 156,000 13% 2%
4" Concrete Block 1040 Blocks 37,440 3% 1%

Total material cost

1,243,505

Additional FBE coating

7.98 Tonnes 87,780 7.1% 1.2%
@ Rs. 11,000/PMT

Source: https://www.materialtree.com/30-50-house-construction-cost/
Life cycle cost analysis of house with/ without FBE coating
Period
PV % GWT FV
(Yrs)
1,243,505 4% 25 3,314,981
87,780 12% 25 1,492,266
Saving 1,822,715
194,998* 12% 25 3,314,981
107,218
*Present value of replacement is the saving in
cost of Rs 33.15 lakhs life time cost
Assuming life of RCC structure of 25 years with plain bars, and annual inflation of 4%, present
cost of house construction will work out to be Rs 72.6 lakhs after 25 years and after 45 years it
will be Rs. 105.78 lakhs.
With FBE usage the repairs will be not be needed even after 45 -50 years. Considering projected
cost of replacement at 6% annually will be 72.63 lakhs, incurring a saving of Rs 72.63 lakhs at 25th
year.
Thus using FBE grade TMT is much more beneficial in house construction